Installation and maintenance of ABG423 paver

The ABG423 paver is a construction machine driven by hydraulic pressure and electronically controlled, used for laying various types of road pavings. The variation range of the paving width is 2.50-12.00 meters, the paving production rate can reach 500 tons per hour, and the capacity of the receiving hopper is approximately 14 tons. The ABG423 paver of our bureau was purchased in 2001. After three years of use, the operation of the paver is considered relatively easy. Although maintenance is rather difficult to master, as it is an imported machine, there won't be any major malfunctions in the next few years. The difficulty lies in the installation and maintenance of the paver. The installation and maintenance of pavers affect the normal operation of the machinery, the construction progress and the flatness of the paving. Based on practical work experience, let's discuss the installation and maintenance of the spreading machine below.

Installation of the paver

1.1 Installation of the operation shed

When installing the tarpaulin with pull strips on the edge, they should face forward or backward.

When installing the fabric with pull rings on the edge, it should be done in the left or right direction.

1.2 Specifications, Installation and Inspection of Screw Conveyors

(1) Specification

The large blades are 420 degrees

Small leaves 360 degrees

(2) Principle:

The screw feeder automatically and steplessly changes speed (0-90r/ min) under the control of the ultrasonic level gauge.

(3) Optional:

The height of the screw conveyor is determined by the thickness of the spread. When the spread thickness increases or decreases, the height of the hydraulic motor hanging box should be raised or lowered. After adjusting to the optimal position, tighten the fixing bolts.

The width of the screw conveyor is determined by the spreading width. The distance between the end of the final selected screw conveyor and the edge plate of the screed should be within the range of 30 to 75cm.

(4) Adjustment

There are no special technical requirements. The main focus is on mastering axial concentricity.

(5) Testing

When the screw conveyor is in operation, try to adjust it to rotate smoothly (by feeling the vibration force of the front baffle plate of the screw conveyor with your hand).

1.3 Specifications, Installation and Inspection of the ironing plate

(1) Specification

2.5m(host) 1.5m(4 pieces on the left and right) 0.5m(2 pieces on the left and right) 1 meter (2 pieces on the left and right); 0.25m(2 pieces on the left and right).

(2) Sequence:

On the left (from the outside to the middle), 0.25m→1.0m→0.5m→1.5m→1.5m→ the main unit.

On the right (from the outside to the middle), 0.25m→1.0m→0.5m→1.5m→1.5m→ the main unit.

(3) During installation, pay attention to adjusting the consistency of the bottom surface of adjacent ironing plates and the front guard strips. The adjustment method: If the bottom of the ironing plate is uneven, adjust the bolts of the lifting lugs on both sides to achieve uniformity. When the front guard strip of the ironing plate is uneven, use a crowbar to move the screw holes of the ironing plate to make it level.

(4) Sag adjustment

① Inspection: Pull a string from both ends of the ironing plate and measure the distance between the middle of the ironing plate and the straight line with a meter stick.

② Adjust the data: When spreading cold material with a width of 12 meters, the sag is generally 2-2.5cm; when spreading hot material with a width of 12 meters, the sag is generally 2.5-3cm.

③ Adjustment method: When adjusting, the ironing plate must be suspended. Use a crowbar to adjust the length of the ironing plate's pull rod.

(5) The adjustment of the road arch can only be carried out after the sag has been properly adjusted

① Inspection: Pull a string from both ends of the ironing plate and measure the distance between the middle of the ironing plate and the straight line with a meter stick.

② Adjust the data: Based on the data provided by the construction unit, refer to the scale marked on the paver for adjustment.

③ Adjustment method: When adjusting, the ironing plate must be suspended. Use a crowbar to adjust the length of the ironing plate's pull rod.

The adjustment of overheight must be carried out when the paver is in operation

① Adjust in accordance with the construction design specifications.

② Adjust by using the technical pile number decomposition method.

The distance between the edge plate of the ironing board and the steel wire is 0 to 35cm.

The selected height of the steel wire rope for the paver should be 10 to 15cm higher than the false laying height.

1.5 Setting and adjustment of paving thickness

(1) Setting of paving thickness: The paver automatically defaults based on the height of the screed, but the indicator light of the longitudinal slope gauge must be adjusted to the off state.

(2) Adjustment of the elevation Angle: When the auxiliary adjustment bolt behind the elevation Angle floating scale is set to zero, the scale displayed on the front floating scale indicates the paving thickness. When the paving thickness exceeds the indicated range of the front elevation Angle floating scale, the rear auxiliary adjustment bolt of the elevation Angle floating scale must be adjusted (the rear auxiliary adjustment scale showing 1 scale is equivalent to the front floating scale showing 5 to 8 scales). When the paving thickness is within 8cm, the elevation Angle auxiliary adjustment bolt must be adjusted to the zero position.

(3) Setting of the elevation Angle floating scale:

Compaction thickness + virtual paving coefficient of the paver (determined by the vibration frequency of the paver)+ set data (generally 3-5cm)- elevation Angle auxiliary adjustment scale.

1.6 Working Principle and Installation of the Tamper

(1) The working principle of the tamper: Driven by a hydraulic motor, it performs regular and inconsistent hammering, thereby increasing the density of the spread.

(2) Selection of the ramming hammer: Install the one with a small slope close to the ironing plate. Install those with larger slopes close to those with smaller ones.

(3) Installation of the ramming hammer

When adding a 25cm or 50cm ironing hammer, only the screw holes on one side of the hammer can be selected for fixation.

② The contact side of the ramming hammer plate must be level and close to the protective strip of the ironing plate.

③ The contact surface of the ramming hammer plate must be at the same level as the lower surface.

1.7 Selection and installation of the connecting shaft of the tamper and the connecting shaft of the vibration

(1) Optional: Tamping hammer connection shaft (longest, shortest): The remaining ones are vibration connection shafts.

(2) Installation of the connecting shafts of the ramming hammer: Starting from one end of the ironing plate, mark each connecting shaft with the letter "H" as the symbol and rotate it in a certain direction by 90 degrees apart.

(3) Installation of the vibration connection shaft: Starting from one end of the ironing plate, use the hexagonal screws inside the shaft key as marks and install them in a straight line in sequence.

When installing the ironing plate and the support rods of the material guard plate, the adjustment ends must be advanced or elevated, leaving sufficient adjustment space.

1.9 Inspection and adjustment of tracks

(1) Inspection: Observe that the natural sag of the front guide wheel and the front drag wheel should be 2-3cm.

(2) Adjustment: Connect the elevation Angle hydraulic cylinder to the track tensioning valve hole with an oil pipe. Open the bypass switch of the cylinder and use the manual control switch of the elevation Angle hydraulic cylinder to automatically tensify with the hydraulic oil. When the tightness is high, the track tensioning valve can also be used to release it.

1.10 Specifications, models and working principles of the longitudinal slope meter

Specification and Model: 8822-091, 8823-091

(2) Working principle: The longitudinal slope gauge is installed at the edge of the screed. It receives signals by moving the sliding rod, analyzes and positions them, and then uses a circuit to control the hydraulic system to correct the screed's elevation Angle at any time according to the paving thickness.

(3) Inspection: The engine should reach the working state, the travel governor should be adjusted to zero position, the automatic screed spreading system should be started, the height of the moving slider should be changed by hand, and the sensitivity of the floating scale of the elevation Angle should be observed.

(4) Adjustment: After installation is completed and the thickness of the ironing plate is determined, turn the up and down adjustment handles of the longitudinal slope meter bracket to keep the indicator light off.

1.11 Specifications, models and application scopes of the transverse slope gauge

(1) Specification and Model :2371-081 2341(Manual Controller model)

(2) Scope of application: It can be used within a paving length of 7 meters.

1.12 Specifications, models and working principles of ultrasonic level gauges

Specification and Model: 41431-091, 41419-091

(2) Working principle: The ultrasonic level gauge is installed at the edge of the ironing plate. It mainly relies on ultrasonic waves to obtain signals for analysis and processing, and then uses a circuit to control the control method of the hydraulic system to control the rotational speed of the screw conveyor (it can also control the start switch of the hydraulic motor of the scraper).

(3) Inspection: The engine is in working condition. Adjust the walking speed regulator to zero, start the automatic system of the screw conveyor and the scraper, cover the ultrasonic emission point of the material level gauge with your hand, and observe the rotational speed of the screw conveyor.

1.13 Factors Affecting the smoothness of paving

(1) Weight of the ironing plate: In principle, this is a constant factor. Due to the effect of the centrifugal force of the vibrator during operation, the weight of the ironing plate also varies with the change in the rotational speed of the vibrator's hydraulic motor. Therefore, the rotational speed of the vibrator's hydraulic motor should remain constant during the paving process.

(2) Walking speed: It should be maintained at a constant speed.

(3) The rotational speed of the vibrating hammer: It should be kept at a constant speed.

2. Maintenance of pavers

2.1 Grade of oil used for pavers

Diesel: Domestic diesel must meet the grade of -10 or lower (according to the German DIN standard, the fuel flow rate must not exceed 0.30%).

Engine oil: Great Wall brand

Winter: CD-grade 15w/30 Summer: CD-grade 15w/40

Butter: Mobil Grease MP grade NLGI-2(must be heat-resistant and have good fluidity)

Gear oil: Hyperbolic (9AE-90)

Antifreeze: Provided by Mobil and Deutz.

2.2 Engine Maintenance

(1) Engine oil and oil filter element

For new engines or those put back into use, they should be replaced after 50 working hours.

When the engine is used normally, it should be replaced after 1,500 working hours.

Diesel filter element: It depends on the condition of the engine. It must be replaced after 300 hours of operation (1000 hours as specified in the manual).

(2) Maintenance of the main filter element

The maintenance of the main filter element is best carried out when the vacuum gauge indicates the need. Frequent disassembly and installation of the filter element may damage the seal between the filter element and the filter. Therefore, the filter element should only be cleaned or replaced when the red warning signal indicates the need. When the filter element has been cleaned 4 to 5 times or accumulated too much dust, it should be replaced with a new one. After removing the filter element, do not blow compressed air into the filter housing. The maintenance frequency of the main filter should be recorded on an appropriate chart.

① Dry cleaning (temporary maintenance)

Gently tap the surface of the filter element straight up and down or wipe off the surface dust with a soft cloth. Be careful not to damage or crush the surface of the filter element.

② Dry cleaning (centralized maintenance)

The filter element can be blown clean with compressed air, but the air pressure should not exceed 5Ba. Moreover, the air nozzle should face the filter element at an Angle and be at least 30 centimeters away from it, blowing from the inside out.

③ Wet cleaning

The filter element can also be rinsed clean in wet water or a cleaning agent. If necessary, it can be rinsed with clean water again. Then, shake off the water and air dry it appropriately. Do not clean it with gasoline, kerosene or hot liquids.

④ Check the seal between the filter element and the filter housing. If any damage is found, a new one needs to be replaced.

⑤ Check if the filter element is leaking or damaged. You can insert a light bulb into the filter element and pass through the penetrating light to observe if there is any damage. If damage is found, a new one needs to be replaced.

Note

Do not run a diesel engine without a main filter. If the vacuum gauge still indicates the original vacuum degree after maintenance or if the main filter is damaged, the main filter element and the safety filter element should be replaced.

(3) Maintenance of safety filter elements

Do not clean the safety filter element. It can only be replaced together with the main filter element after the main filter element has been cleaned five times. The replacement interval of the safety filter element usually should not exceed two years.

(4) Maintenance of the ash discharge valve

The dust discharge valve requires no maintenance. It only needs to be squeezed once every two weeks to release hard dust particles.